Sun visor with clam shell core attachment snaps

ABSTRACT

A sun visor has a plurality of receivers and projections defining snap connections for securing first and second core halves in a folded over, closed position. The receivers are carried on one of the core halves and include angularly extending latch arms. The projections are carried on the other core half and have an enlarged head insertable through the spaced ends of the latched arms such that the latch arms snap underneath the head into engagement with a stem of each projection to lock the projection in the receiver.

BACKGROUND

The present invention relates, in general, to vehicle sun visors.

Sun visors are used in vehicles to provide front and side windowprotection from sunlight entry. Such sun visors are pivotal about alongitudinal axis between a stowed position adjacent the headliner and adeployed position angularly extending from the headliner. Most sunvisors can also be unlocked from a headliner mounted clip or D-ring andpivoted to the side window about a support arm attached to the vehicleheadliner. A biasing means is typically mounted within the visor toprevent movement and noise when the sun visor is in the stowed position.

Over the years, various enhancements or features have been added for sunvisors to increase their versatility as well as to add other conveniencefactors to the vehicle occupants.

One such feature is the telescopic extension of the entire sun visoralong the longitudinal axis of the support arm to enable the sun visorto be repositioned laterally across the windshield or the side window toblock sun light entry in a particular direction for an occupant.

Another common feature is a mirror with or without a pivotal cover andwith or without an illumination means which is mounted in one surface ofthe sun visor, typically the surface facing the headliner when the sunvisor is in the stowed position. The sun visor need only be pivoted tothe angular downward extending position to allow use of the mirror.

When an illumination means, such as lamps, are provided around themirror, electrical conductors or wires extend through the A pillar ofthe vehicle body and the support arm to the individual lamps in the sunvisor.

Various means have been provided to mount fabric or decorative coversover the plastic sun visor core. One such mount traps the ends of thefabric cover between the two clam shell core halves when the halves aremoved to their closed, locked position. Another mount utilizesprojections on the inner surfaces of the core halves over which theinner edges of the fabric cover are forced.

Heat stake projections have also been provided about the periphery ofthe core halves. In this mounting technique, the edges of the fabriccover are forced over the heat stake projections and then heat isapplied to melt the stakes through the interstices of the fabric coverto fixedly retain the inner edges of the cover in a fixed position onthe sun visor core.

SUMMARY

The present invention is a sun visor having unique clam shell coreattachment snap lock means.

In one aspect of the invention, the sun visor includes a core formed offirst and second foldable core halves each pivotal about a common hingeedge. A plurality of receivers are mounted on the first core half, eachreceiver formed of at least a pair of latch arms extending angularlyfrom the core halves toward each other.

A plurality of projections are formed on the second core half, eachprojection having a stem extending from the second core half and anenlarged head, the first and second latch arm having ends which aredisplacable when the head of the projection is inserted therethroughwherein the ends of the latch arms snap underneath the head intoengagement with the projection to lock the projection in the and to lockthe first and second core halves in a fully assembled, closed position.

In one aspect, the head defines a pair of opposed edges extendinglaterally outward from the stem, the edges engagable with the latcharms.

In another aspect, the latch arms are disposed at an acute angle withrespect to a plane through a major extent of the second core half.

Each of the latch arms is normally spaced apart by a distance less thanthe dimension of the outer periphery of the head of the projection.

The sun visor with attachment snaps provides a unique attachment for sunvisors having foldable core halves which provides easy insertion of onepart into the other part while providing a high level of pull-out orseparation force resistance to prevent inadvertent opening of the foldedover core halves of the sun visor core. The unique snap attachments ofthe present invention provide increasing separation force resistancewhen force is exerted in a direction to separate the snap portions fromeach other.

Other applications of the present invention will become apparent tothose skilled in the art when the following description of the best modecontemplated for practicing the invention is read in conjunction withthe accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWING

The various features, advantages and other uses of the present inventionwill become more apparent by referring to the following detaileddescription and drawing in which:

FIG. 1 is a perspective view of a completely assembled sun visoraccording to one aspect of the present invention;

FIG. 2 is an elevational view of an open clam shell core for the sunvisor shown in FIG. 1, depicting the initial step of attaching thefabric cover to the core;

FIG. 3 is an enlarged, cross-sectional view of one corner of the clamshell core in the closed position showing the edge fold and edgematerial attached to the core;

FIG. 4 is an enlarged, perspective view of the corner of the core shownin FIG. 3;

FIG. 5 is an exploded, perspective view of the slide carrier, clip andlarge support rod according to one aspect of the present invention;

FIG. 6 is a cross sectional view showing the slider carrier, clip andsupport rod in a closed core position;

FIG. 7 is a perspective view of the sun visor of FIG. 1 depicting theslider means in the normal, retracted position;

FIG. 8 is a perspective view similar to FIG. 7, but showing the slidecarrier in the fully extended sun visor position;

FIG. 9 is a perspective view of the sun visor of FIG. 1 having a shortlength, non-telescoping support arm;

FIG. 10 is a perspective view of another aspect of the sun visoraccording to the present invention shown in an open core position anddepicting the mounting of a mirror to one core half;

FIG. 11 is a perspective view of a completed sun visor showing oneaspect of a fully optioned mirror assembly with a cover deployed in aclosed position;

FIG. 12 is a perspective view, similar to FIG. 11, but with the coverdeployed in an open position;

FIG. 13 is a cross-sectional view through the sun visor of FIG. 11depicting the mounting of the mirror assembly to the core and cover;

FIG. 14 is a perspective view of another aspect of a sun visor accordingto the present invention having a mirror assembly mounted therein; and

FIG. 15 is a cross-sectional view of an alternate aspect of the sunvisor of the present invention.

DETAILED DESCRIPTION

Referring now to the drawings, and to FIGS. 1-14 in particular, there isdepicted a sun visor denoted generally by reference number 10 whichincludes a number of features, all described hereafter, which may beused in various combinations as well as individually, separate from theother features.

In general, the sun visor 10 includes a core 12, a cover 14 typicallymade of fabric, including synthetics and natural fabrics, a support armformed of either a long length support arm 16 allowing telescopingmovement of the sun visor 10 as described hereafter and as shown inFIGS. 7 and 8 or a short length support arm 18 shown in FIG. 9 whichdoes not provide telescoping extension of the sun visor 10. The sunvisor 10 may also include a mirror assembly shown in various featurecombinations in FIGS. 11-14.

Referring now to FIGS. 2-4, the core 12 is in the form of a clam shellhaving a first clam shell portion or half 20 and a second portion orhalf 22. The core 20 is formed of a suitable, light weight, easilyformed material, such as plastic. A plastic useable to form the core 12maybe polypropylene, by example only.

The first and second core halves 20 and 22 are integrally and pivotallyjoined together along a living hinge portion or edge 24 extendingbetween one longitudinal edge of each of the core halves 20 and 22.

The core halves 20 and 22 have a substantially mirror imageconfiguration formed of opposed longitudinal edges joined together toform the living hinge 24, outer longitudinal edges 26 and 28, adjacentside edges 30 and 32, and adjacent side edges 34 and 36. The side edges26 and 28 may optionally be formed as part of a pivotal flap sectionpivotable about a second living hinge or weakened portion 38 formedadjacent from each side edge 26 and 28.

As shown in FIGS. 1 and 2, an intermediate portion between the sideedges 30 and 32 and an intermediate portion 40 between the side edges 30and 32 of the first and second core halves 20 and 22, respectively, isrecessed to form a space for insertion of one support arm 16 or 18 intothe core 12. An end portion of the living hinge 24 between the corehalves 20 and 22 is formed with an aperture 42 which, when the core 12is in the closed, fully assembled position shown in FIG. 1, defines anopen ended recess adapted for receiving a D-ring 44 for securing one endof the sun visor 10 to a latch member mounted in a vehicle head liner,not shown. The D-ring 44 is mounted in the core 12 by suitable clips,not shown.

The core 12 of the present invention is provided with a unique covermounting means which insures a quick and secure mounting of the cover 14on the outer surface of the core 12.

The cover mounting means includes an elongated, elevated coverattachment surfaces 50 and 52 respectively formed in the core halves 20and 22. Each surface 50 and 52 is formed as one elongated projectionextending between the side edges 30 and 34 and the side edges 32 and 36or in a discontinuous fashion formed of multiple segments orprojections. Each surface 50 and 52 terminates in a suitably formedouter mounting surface 54 and 56, respectively. Each surface 54 and 56may be planar or have any other shape, such a smoothly curved concave orconvex shape.

In the aspect of the surfaces 50 and 52 shown in FIGS. 2 and 3, eachsurface 50 and 52 has a generally C-shape, formed as a continuous memberprojecting outward from the main extent or plane of the core halves 20and 22.

In attaching the cover 14 to the core 12, the core 12 and the cover 14are juxtaposed as shown in FIG. 2 with cover 14 overlaying an outersurface of the core 12. In this arrangement, the outer peripheral edgeof the cover 14 shown by reference number 58 projects outward beyond theperiphery of the side edges 30, 32, 34 and 36 of the core 12. The outerperipheral edge 58 of the cover 14 is then folded over a peripheral lip60 and 62 on each core half 20 and 22 and inward to a position in whichthe peripheral edge 58 of the cover 14 is in contact with and overlayseach of the surfaces 54 and 56 on the surfaces 50 and 52. Sonic wavesare then applied to the surfaces 50 and 52 to cause molecular vibrationand melting of the surfaces 50 and 52 into the interstices of the coverthereby joining the cover 14 to the core halves 20 and 22, aftercooling, in a secure connection or joint which extends substantiallycontinuously about the entire periphery of the core 12.

As shown in FIGS. 2-4, alignment and stability enhancing members 70, 72,74 and 76 are formed in complimentary positions in the core halves 20and 22 so as to be disposed in close proximity with an opposed member,with contact also being possible, as shown in FIGS. 3 and 4, when thecore halves 20 and 22 are folded into the closed, fully assembledposition. The alignment members 70, 72, 74 and 76 may take any shape,with the generally angular, L-shape shown in FIG. 2 by way of exampleonly.

Lock means are provided for securing locking the core halves 20 and 22in a fully assembled, closed position shown in FIGS. 3 and 4. The lockmeans comprises a plurality of posts denoted generally by referencenumber 80 which are formed of a stem 82 and a head 84 having a radiallyoutward extending periphery formed of at least two side arms 86 and 88.Rather than just two side arms 86 and 88, the entire periphery of thehead 84 may be enlarged to a greater diameter or cross-section dimensionthan the diameter or cross-section of the stem 82 so as to provide anenlarged head which overhangs the outer periphery of the stem 82 asshown in FIG. 3. The posts 80 are deployed at a number of locations onone of the core halves 20 and 22, with the post 80 being shown by way ofexample only as being mounted on the core half 22.

A plurality of lock receivers 90 are formed in the other core half 20.The lock receivers 90 include an outer wall formed of at least two wallportions 92 and 94, with additional wall portions, including a thirdwall portion and even a fourth wall portion to form walls 92, 94, 95 and97 as a completely closed, continuous wall may also be employed. Lockmembers are resiliently mounted on and extend from an end of at leasttwo of the side walls 92 and 94. The lock members all denoted generallyby reference number 96 include a leg 98 which terminates in an outer end100. The legs 98 of the lock members 96 are disposed at an acute anglefrom the adjacent side wall 92 or 94 such that the outer end 100 ispivotal about the connection between the legs 98 and the adjacent sidewalls 92 and 94 of each receiver 90. This pivotal movement allows thehead 84 of a complementarity positioned lock post 80 on the mating corehalf 22 to slide through the space normally existing between twoadjacent lock legs 98 thereby urging the outer ends 100 outward untilthe head 84 snaps past the outer ends 100 of the legs 98. The legs 98then snap back toward the nominal position and seat against a shoulderformed between the inner surface of the side arm 86 and 88 of the head84 and the adjacent outer surface of the stem 82 thereby securelylocking the lock post 80 in the receiver 90. The same locking processoccurs across the entire core 12 at every location of a matinglypositioned receiver 90 and lock post 80.

Referring again to FIGS. 1 and 2, and in greater detail in FIGS. 5 and6, the support arm 16 is mounted within the core 12 prior to lockingclosure of the core halves 20 and 22 as described above. The support armmay take one of two configurations, including the telescoping, longlength support arm 16 shown in FIGS. 7 and 8 and the shorter lengthsupport arm 18 shown in FIG. 9 for non-telescoping sun visors.

Regardless of the length of the support arm 16 or 18, the end portion ofeach support arm 16 or 18 includes at least one and preferably a pair offlats 110 adjacent an outer end 112, with only the support arm 16 beingdepicted in FIG. 5 by way of example only. The remainder of the supportarm 16 may have a circular cross-section, by example only. A stop flange114 is spaced from the outer end 112 of the support arm 18 to retain thesupport arm 18 in a slide carrier 120. The carrier 120 defines anintegral, one piece body, typically of a molded plastic, having a pairof side arms 122 and 124, each with an aperture 126 and 128,respectively, the apertures 126 and 128 being coaxially aligned forreceiving the end portion of the support arm 18 with the flats 110disposed between the side arms 122 and 124.

A first pair of apertures 130 are formed in a central leg 132 of theslider 120. A second pair of apertures 134 are also formed in thecentral leg 132 of the slider 120. The pairs of apertures 130 and 134receive bent edges 136 and 138 of a spring clip 140 to attach the springclip 140 to the slider 120. The spring clip 140 has an enlarged endportion denoted by reference number 142 which receives the end portionof the support arm 16. A pair of bent portions 144 and 146 on the springclip 140 resiliently engage the flats 110 on the end of the support arm18 to exert a biasing force tending to retain the entire sun visor 10 ina fixed position, typically biased in a direction toward the vehicleheadliner in a normal, stored sun visor position to minimize buzz,squeaks or rattles. This provides the necessary noise control featuresfor the sun visor 10 of the present invention.

The sun visor 10 has a unique telescoping mount using the slide carrier120 which may be used by itself or in combination with the heat stakecover attachment described above as well as with or without any of theadditional unit features of the sun visor described hereafter.

The slide carrier 120 includes first and second, oppositely directed,open ended channels 150 and 152 which are integrally formed in thecarrier 120. The open end of the channel 150 extends oppositely from theopen end of the channel 152. The channels 150 and 152 are positioned toengage slide rails 154 and 156, shown in FIGS. 2, 6, 7 and 8 which areintegrally formed as part of the core halves 20 and 22, respectively.The slide rails 154 and 156 extend along the length of each core half 20and 22, generally in parallel with the hinge 24.

When the core halves 20 and 22 are locked in the fully assembled, closedposition shown in FIG. 6, the slide rail 154 engages the channel 150 andthe opposed slide rail 156 engages the opposite channel 152 in theslider 120. This dual, opposed slide rail and channel configurationsecurely retains the slider 120 in a constant orientation during alltelescoping movement of the sun visor 10 relative to the support arm 16as described hereafter. The addition of the second channel 150 and theslide rail 154 provides added stability to insure a smooth, evenbi-directional telescoping movement of the sun visor 10 along thesupport arm 16 while at the same time securely retaining the sun visor10 to the support arm 16.

FIG. 7 depicts the normal, non-telescope position of the sun visor 10relative to the support arm 16. In this position, the carrier 120 isdisposed adjacent to the D-ring end of the sun visor 10. When thevehicle occupant desires to laterally extend the position of the sunvisor 10 relative to the support arm 16, the occupant grasps the sunvisor 10 and slides the sun visor 10 along the support arm 16 to anyposition up to a maximum extend position shown in FIG. 8. In the maximumextended position, the carrier 120 is disposed adjacent to a support armpivot support or clip 160. The clip 160, shown in FIGS. 7, 8 and 9,includes a wall integrally formed on one of the core halves, such as thesecond core half 22 having an aperture 162 for receiving the support arm16 therethrough. The portion 164 of the wall 160 carrying the aperture162 is spaced from a collar 166, also formed on the core half 22, whichdefines a generally circular cross-section bore through which thesupport arm 16 extends.

The sun visor 10 may also be provided with the short length support arm10 for non-telescoping use without any modifications to the core 12. Byexample only, the non-telescoping aspect of the present sun visor 10also employs the carrier 120, the support wall 160 and the sleeve 166.However, the carrier 120 is non-laterally moveably disposed within thewall 160 as shown in FIG. 9.

Referring now to FIGS. 10-14, there is depicted several aspects of amirror assembly which may be optionally employed with the sun visor 10of the present invention. It will be understood that the various aspectsof the mirror assembly described hereafter are useable independently orin combination with any of the telescoping, fabric cover mount or corelock means described above.

In one aspect of a mirror assembly shown in FIG. 10, which preferablyapplies to all the mirror assemblies described hereafter, a shallowrecess 170 is formed in the core half 22 projecting slightly out of theplane of the main extent of the core half 22. The recess 170 is formedby a wall 172.

At least one and preferably a plurality of spaced apertures 174 areformed in the wall 172. Each aperture 174 is alignable with acorresponding lock receiver 90 on the mating core half 20. Each aperture174 is positioned to receive a lock post 80, identical to the lock post80 described above for locking the core halves 20 and 22 in the fullyclosed, assembled position, but now provided on a back plate 176 of aframe or mirror support. The lock posts 80 project from the back wall orplate 176 so as to extend through the apertures 174 and the wall 172 andinto locking engagement with the mating receiver 90 when the core halves20 and 22 are pivoted to the fully closed position. This enables themirror assembly to be fixedly attached to the core 10 at the same timethe core halves 20 and 22 are locked in the closed, fully assembledposition.

FIGS. 11 and 12 depict an opposite surface of the core half 22 which hasthe recess 170 formed therein for receiving a mirror assembly 182. Inthis aspect of the mirror assembly 182, the mirror assembly 182 includesa moveable or pivotal cover 184 which is pivotally mounted to a frame186 formed of a fixed frame member 188 attached to the back plate 176shown in FIG. 10 and a mirror surround frame 190, only a portion ofwhich is shown in FIG. 11. The cover 184 has a generally planar extent,with depending side walls and a raised edge 192 to permit easy pivotalmovement of the cover 184 between open and closed positions shown inFIGS. 12 and 11, respectively. A hinge 189 is provided between a fixedframe element 188 and the cover 184.

The mirror assembly 182, as shown in FIG. 12, also is provided with anillumination means in the form of one or more lamp means 196 and 198mounted in the mirror surround frame 190 on at least one and preferablyopposed sides of a reflective mirror 200. The mirror 200 is typicallyadhesively joined to the back plate 176. Conductors for conducting powerto the light means 196 and 198 located below the bezzles or lenses 202are routed between the closed core halves 20 and 22 and into an apertureformed in the support arm 16 or 18 whereby the wires exit the sun visor10 and pass through the vehicle interior, typically through the vehicleA pillar to the accessory power vehicle circuit.

According to a unique aspect of the present invention, the mirrorassembly 182 is mounted on the sun visor 10 after the core halves 20 and22 of the sun visor 10 have been pivoted to the closed, latchedposition. As shown in FIG. 13, the lock post 80 may be forced throughthe fabric cover 14 into the underlying receiver 90 to fixedly mount themirror assembly 182 to the sun visor 10. The layer of the cover fabric14 disposed between the back wall 176 of the mirror assembly 182 and thecore half 20 minimizes the generation of buzzes, squeaks and rattles.

It will be understood that the mirror assembly 182 may be providedwithout the lamp means 196 and 198 and with or without the pivotal cover184. Another mirror assembly 210 is depicted in FIG. 14. In this aspect,the mirror apparatus is formed of a multi-sided frame 212 whichsurrounds a mirror 214 secured, typically by adhesive, to a back plate,not shown. The back plate can be identical to the back plate 176 so asto carry the lock posts 80 for secure attachment of the mirror assembly210 to the core half 22 as described above.

As shown in FIG. 15, the core 10 having the recess 172 formed in one ofthe core halves for receiving one of the mirror assemblies describedabove, may also be utilized without any mirror assemble. In thisapplication, a filler member 220 has a peripheral shape complementary tothe shape of the recess 170 in the core half 22 and a thicknesssubstantially the same as the depth of the recess 170.

In use, the filler member 220 is mounted within the recess 170 andcovered by the cover 14 which holds the filler member 220 in the recess170. Alternately, the filler member 220 may be fixed in the recess 170by means of adhesive, etc.

The use of the filler member 220 provides a flush surface with thesurrounding surface of the core half 22 when a mirror assembly is notused in the sun visor 10. At the same time, the filler member enables asingle core 12 design to be employed with and without a mirror assemblywithout requiring any modification or additional manufacturing cost.

In summary, there has been disclosed a unique vehicle sun visor havingimproved fabric cover attachment, easy and reliable telescoping visormovement, the option to switch between a telescoping support arm and afixed short support arm without modification to the sun visor core so asto contribute to a reduced manufacturing cost, multiple mirror assemblymounts, unique and reliable core lock members, and a mirror attachmentmeans which controls or minimizes the generation of noise between thecontacting parts of the mirror and the sun visor core.

What is claimed is:
 1. A sun visor comprising: a core having first andsecond foldable halves; a plurality of receivers mounted on the firstcore half, each receiver including spaced sidewalls projecting from thefirst core half, and at least a pair of latch arms, each invertinglyangularly extending from an end of one sidewall into a space between thesidewalls; a plurality of projections carried on the second core half,each projection having a stem extending from the second core halfterminating in an enlarged head, the head engagable through the latcharms to fixedly join the projection to the receiver when the first andsecond core halves are folded over each other to hold the first andsecond core halves in a folded over, closed position; and ends of thelatch arms snappingly engaging the projection at an edge formed betweenthe head and the stem to resist separation between of the projectionfrom the receiver.
 2. The sun visor of claim 1 wherein the headcomprises: at least a pair of opposed edges extending radially outwardfrom the stem, the edges engagable with the latch arms to deflect thelatch arms away from each other during insertion of the projectionbetween the latch arms.
 3. The sun visor of claim 1 wherein: the latcharms are disposed at an acute angle with respect to the first core half.4. The sun visor of claim 1 wherein: the ends of the latch arms arenormally spaced apart a distance less then an outer peripheral dimensionof the head of the projection.
 5. The sun visor of claim 1 furthercomprising: means for maintaining the sidewalls in a substantiallystationary position.
 6. The sun visor of claim 5 wherein the maintainingmeans comprises: at least one wall portion connecting the spacedsidewalls to prevent substantial movement of the sidewalls relative toeach other.
 7. The sun visor of claim 6 wherein the at least one wallportion comprises: a pair of wall portions interposed between andconnected to the sidewalls and forming a continuous wall with thesidewalls.
 8. The sun visor of claim 5 wherein: the latch arms aredisposed at an acute angle with respect to the first core half.